Metal forming apparatus

ABSTRACT

The combination of a self-adjusting payoff and a compact, portable metal forming device comprising: 1) a frame having entry and exit ends; 2) guide means adjacent the entry end for guiding a sheet of metal to be formed to a hand operated drive assembly supported within the frame that engages the metal sheet and drives it, through the operation of a series of gear linked separately journaled forming roll pairs mounted in the frame, 3) adjacent the exit end an adjustable cam wheel that engages one edge of the metal sheet and forms that edge just prior to the metal sheet reaching the exit end, and 4) forming the exit end, a guillotine cutter including a shaped exit aperture for cutting the formed metal sheet to any selected length.

This application is a continuation-in-part of U.S. patent applicationSer. No. 09/546,424 filed Apr. 10, 2000 entitled “Metal FormingApparatus”, now U.S. Pat. No. 6,282,935.

FIELD OF THE INVENTION

The present invention relates to equipment for the on-site fabricationof metal roofing flashing and the like and more particularly to portablesuch equipment that is easily transported from site to site.

BACKGROUND OF THE INVENTION

The fabrication of metallic flashing and the like for use in theinstallation of roofs is largely a custom operation generallynecessitating that fabrication be performed on site. As a rule, suchfabrication is done by hand using small metal bending equipment such asportable metal breaks or the like using metal cut from a coil or insheet form that is carried to the job site. Often the width of asuitable section of, for example flashing must be cut from an oversizedcoil or sheet marketed to meet the needs of a broad range of customers,but not specifically meeting the needs just described. Such on sitefabrication for common shapes in custom lengths is therefore often verytime consuming and therefore costly for the installer and ultimately thecustomer.

While there exists a large number of metal forming devices most are verylarge and cumbersome, often requiring independent power sources andtherefore very costly or requiring a dedicated vehicle for theirtransportation. The use of such large devices is therefore not practicalfor the average roofer, even one performing a large number of roofingjobs that require the on site fabrication of a number of commonlyshaped, but custom length flashing parts.

The availability of a compact, inexpensive and readily hand operatedmetal former capable of forming metal flashing and the like in customlengths that can be transported in, for example, an ordinary pick-uptruck without occupying an undue amount of cargo space would, therefore,be of significant value to the roofing community.

OBJECT OF THE INVENTION

It is therefore an object of the present invention to provide a compact,low cost and preferably hand operated metal forming device that meetsthe needs of the roofing community for the on-site, custom fabricationof metal flashing and the like.

SUMMARY OF THE INVENTION

The present invention provides a compact, portable metal forming devicecomprising: 1) a frame having entry and exit ends; 2) guide meansadjacent the entry end for guiding a sheet of metal to be formed to ahand operated drive assembly supported within the frame that engages themetal sheet and drives it, through the operation of a series of gearlinked separately journaled forming roll pairs mounted in the frame, 3)adjacent the exit end an adjustable cam wheel that engages one edge ofthe metal sheet and forms that edge just prior to the metal sheetreaching the exit end, and 4) forming the exit end, a guillotine cutterincluding a shaped exit aperture for cutting the formed metal sheet toany selected length.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of the complete metal forming device of thepresent invention.

FIG. 1a is a side view of the complete metal forming apparatus of thepresent invention showing an alternative payoff device at the entry end.

FIG. 1b is a blown apart perspective view showing a preferred pivotingspool payoff of the metal forming apparatus of the present invention.

FIG. 1c is a partially cutaway view of the pivoting spool payoff of themetal forming apparatus of the present invention.

FIG. 2 is a partially phantom side view of the metal forming device ofthe present invention.

FIG. 3 is a partially phantom top view of the metal forming device ofthe present invention.

FIG. 4 is a partially phantom exit end view of the metal forming deviceof the present invention.

FIG. 5 is a partially phantom entry end view of the metal forming deviceof the present invention.

FIG. 6 is a partially phantom exit end view of the metal forming deviceof the present invention showing the guillotine cutter in the protectedor operating position at the exit end.

FIG. 7 is a partially phantom exit end view of the metal forming deviceof the present invention showing the guillotine cutter in the cuttingposition.

FIG. 8 is a partially phantom, cutaway view showing the final metaledge, forming wheel in a first position.

FIG. 9 is a partially phantom, cutaway view showing the final metaledge, forming wheel in a second forming or bending position.

FIG. 10 is a partially phantom view of the metal forming apparatus ofthe present invention showing the final metal edge forming wheel in thedown or metal forming position.

DETAILED DESCRIPTION

Referring now to FIG. 1, the complete metal forming system 10 of thepresent invention includes a platform 12, a payoff 14, and wherenecessary for mounting, for example, on the side rail of a pick-uptruck, adjustable jacks 16 for that side of platform 12 that is notsupported by the side rail, and metal forming apparatus 18 that is thecore of the present invention. Platform 12 may be fabricated from anysuitable material such as aluminum or steel and for appearance may be ofso-called “diamond plate” high brilliance aluminum. The purpose ofplatform 12 is simply to provide a convenient co-location for payoff 14and metal forming apparatus 18. According to a preferred embodiment,platform 12, as best shown in FIG. 4, has a slanted flange 20 and anorthogonal flange 22 extending downward therefrom. Orthogonal flange 22serves as the location of jacks 16 that can be secured to platform 12 inany suitable fashion (bolts, screws brackets, etc.) and support thatside of platform 12 by bearing against the bed of a pick-up truck (notshown) and the bottom surface 24 of platform 12 when slanted flange 20is laid over the pick-up truck side rail (not shown).

Sheet metal forming apparatus 18 may be permanently or removablyattached to platform 12 in any suitable fashion such as with bolts orotherwise. One preferred method of attachment best shown in FIG. 2utilizes a cut out block 13 removably bolted to platform 12 that engagesbottom 15 of frame 28.

Payoff 14 can be of any suitable design that permits support of a coil26 of metal and allows the controlled extraction of sheet metaltherefrom. Thus, it is highly desirable that payoff 14 be equipped withsome type of friction or brake mechanism to inhibit uncoiling of thesheet metal in an uncontrolled fashion. A specifically preferredalternative payoff is described below.

As will be obvious to the skilled artisan, metal forming apparatus 18 asdescribed hereinafter can be used independently of any platform 12, ifotherwise securely located or without payoff 14, if discrete sheets ofmetal to be formed are introduced thereto.

As previously stated, the core of the present invention is metal formingapparatus 18. As shown in the various Figures, metal forming apparatus18 comprises a frame 28 having an entry end 30, a discharge or exit end32, a top 87, opposing sides 68 and 70 and a bottom 15. Extendingoutward from entry end 30 is a pair of parallel offset guide bars 34 and36 having grooves 38 and 40 respectively therein. Grooves 38 and 40begin the forming process by engaging the edges of an inserted piece ofsheet metal (not shown) and, as the sheet is pushed or advanced therein,because of their offset, aligning the sheet for engagement with theinitial set of forming rolls 42 and 44 described hereinafter. Forpurposes of convenience hereinafter, the metal sheet will be referred toas having a left and a right side, the left side being that whichengages groove 38 and the right side being that which engages groove 40.Insertion of the metal sheet into grooves 38 and 40 as just describedcauses the metal sheet to assume a general U-shape between grooves 38and 40. The presence of this U-shape ease entry of the metal sheet intometal forming apparatus 18. In the absence of the formation of thisgeneral U-shape caused by insertion of the metal sheet edges as justdescribed, the metal sheet will tend to buckle. Such buckling couldalternatively be inhibited by the inclusion of additional forming rolls,but the use of grooves 38 and 40 in offset guide bars 34 and 36 obviatesthe need for such additional forming rolls thereby permittingminimization of the length of metal forming apparatus 18.

In the embodiment depicted in FIGS. 1, 2, and 3, a stiffener assembly 60is shown. Stiffener assembly 60 comprises a brace 62 mounted to brackets64 that are in turn attached to frame 28. An adjustment bolt 66 isthreaded through brace 62 to permit stiffening or fine adjustment offrame 28 when frame 28 undergoes deflection due to the thickness of themetal being formed in metal forming apparatus 18 or otherwise. If frame28 is constructed from sufficiently heavy metal, or metal formingapparatus 18 is used to form only very light metal sheet, stiffenerassembly 60 may be eliminated entirely. Metal forming apparatus 18 inits depicted configuration is capable of forming, for example, aluminumflashing and the like up to a thickness of about 0.030″ and the presenceof stiffening assembly 60 permits loosening or tightening of the formingrolls to accommodate varying thicknesses of metal sheet.

Each of forming rolls 42, 52 and 56 is mounted on its own independentshaft (shafts 63, 65 and 66) that are separately journaled in sides 68and 70 of frame 28. Shaft 63 is extended beyond side 68 to permitattachment of crank or handle72 that serves as the driving means formetal forming apparatus 18. Crank 72 is preferably removably mounted onshaft 63 by provision of engagement portion 74 on handle 72 that slipsover shaft 63 and is fixed in place by the insertion of a pin 76 orother similar fastener that penetrates an aperture 78 in shaft 63 andengagement portion 74. Turning of handle 72 in a clockwise directionthus turns shaft 63 and attached forming roll 42.

Each of drive rolls 44, 54 and 58 that are mounted above and parallel toeach of corresponding forming rolls 42, 52 and 56 also has a shaft 80,82 and 84 journaled in side 70 of frame 28 at one end thereof and inside 86 of internal frame 88 at the other end thereof. Internal frame 28is formed by the addition of downward extending flange 26 from the top27 of internal frame 28. Attached to the ends of shafts 20, 22 and 24are gears 25, 29 and 20.

Attached to extremity 22 of shaft 23 is a principal drive gear 24 thatis also turned when handle 22 is turned in a clockwise direction byvirtue of its connection to shaft 62. Similarly, shafts 84 and 86 havegears 96 and 98 attached to their extremities that penetrate side 70 offrame 28. Each of gear sets 94 and 85, 89 and 96 and 90 and 98 are inengaging relationship with each other. Between each of theabove-described gear sets, is a transfer gear 100 and 102 respectivelythat serves to transfer rotary motion from gear 85 to gear 89 and fromgear 89 to gear 90. Thus, when handle 72 is rotated in a clockwisedirection, rotary motion is transferred from gear 94 to gear 85, fromgear 85 to transfer gear 100, from transfer gear 100 to gear 89, fromgear 89 to gears 96 and 102, from gear 102 to gear 90 and from gear 90to gear 98. Thus, turning of handle 72 causes all of the various gears,shafts and their attached rolls to advance in unison and a piece ofsheet metal introduced into grooves 38 and 40 and brought intoengagement with roll pair 42 and 44 is caused to advance through metalforming apparatus 18.

Forming rolls 42, 52 and 56 include at their extremities opposing thosejournaled in side wall 70 and beyond side wall 86 of inner frame 88enlarged forming portions 104, 106 and 108 respectively that includetapered portions 110, 112 and 114 that are tapered upward toward theseextremities at progressively larger angles so as to progressively formsheet metal inserted between roll pairs 42 and 44, 52 and 54 and 56 and58. Lower edge 116 of side or flange 86 is similarly tapered toaccommodate such metal during deformation or forming.

As will be apparent to the skilled artisan, both guide or drive rolls44, 54 and 58 and forming rolls 42, 52 and 56 should be coated orsurfaced with some appropriate material. In the case of drive rolls 44,54, and 58, an adherent material such as polyethylene or polypropylenethat provides a gripping surface that “grabs” the sheet metal surface asit advances is highly desirable. It may further be desirable to coat theextremities 118, 120 and 122 of drive rolls 44, 54 and 56 near or at thepoints where they meet tapered regions 110, 112 and 114 with a “tougher”material such as Deirin, a nylon material commonly used for rollers andthe like, that presents a tough but “slick” or slippery surface to themetal sheet passing thereover. Delrin or some such similar tough butslippery material is similarly useful as the surface of forming rolls42, 52 ands 56 as well as previously described guide roll 48.

As will further be apparent to the skilled artisan, while formingapparatus 18 depicted herein is shown as having three progressiveforming rolls, a preferred configuration, a system that utilizes as fewas two forming rolls or more than three forming rolls may also beconsidered effective.

Downstream of final forming roll 56 and adjacent to side wall 70 offrame 28 is adjustable edge forming assembly 124. Edge forming assembly124, best seen in FIGS. 8 and 9, comprises an angularly oriented camwheel 126 rotatably attached to an indexable slide arm 128 capable ofmoving up and down (being indexed) within channel bracket 130.Positioning of indexable slide arm 128 and attached cam or forming wheel126 is preferably achieved through location of set bolt 132 inpredrilled apertures 134 and 136 in slide arm 128. Addressing cam wheel126 is guide roll 138. The right edge of sheet metal engaging cam wheel126 is forced between cam wheel 126 and guide roll 138 causing the edgeto bend downward when slide arm 128 is in the down position as shown inFIG. 9, or to pass unformed when cam wheel 126 is in the up position asdepicted in FIG. 8. The particular location of cam wheel 126 will bedependent upon whether or not the final downward bend of the right sheetmetal edge imparted by edge follower assembly 124 is required in theflashing installation for which the metal is being fabricated. Both camwheel 126 and guide roll 138 are preferably coated with or fabricatedfrom Delrin or some similar “tough” and “slick” coating.

Referring now to FIGS. 4 and 5, although it is not critical to thesuccessful practice of the present invention, in order to render thefree end, i.e. that end not contacting forming roll 126, more rigid andtherefore easier to manage and feed through guillotine cutter assembly148, it is preferred to incorporate a pencil beading assembly 194 justupstream from guillotine cutter assembly 148. Pencil beading assembly194 comprises a barbell shaped forming roll 196 that faces a beadingroll 198 such that when sheet metal enters between these two rolls, alongitudinal pencil bead of the type well known in the art is formednear the outer edge of the sheet metal thereby making that edge morerigid. Barbell shaped forming roll 196 and beading roll 198 lie facingeach other on either side of a slot 193 formed in beading block 195.Barbell shaped forming roll 196 and beading roll 198 are both freelyrotating and mounted on shafts threaded or otherwise secured in beadingblock 195. Slot 193 which provides access for the sheet to engagebarbell shaped forming roll 196 and beading roll 198 is preferablyoriented at an angle of about 60° from horizontal so as to engage theedge of the sheet metal being formed and guide it between theaforementioned two pencil bead forming rolls.

The final element of the metal forming apparatus 18 of the presentinvention comprises guillotine cutter assembly 148. Guillotine cutterassembly 148 comprises a cutting arm 150 rotatably attached to frame 28at point 152 and rotatably to connector 154 at a point 156 intermediatethe ends of cutting arm 150. Connector 154 is in turn rotatablyconnected to cutting blade 158 at point 160. Cutting blade 158 isslideably located between a pair of guide plates 162 and 164 that formthe end wall of the exit end of frame 28. Each of guide plates 162 and164 include an exit slot 166 that registers with a similar, butoversized cutting slot 168 in cutting blade 158. Exit slots 166 areconfigured to the shape of the formed sheet metal that will exit metalforming apparatus 18. If cam wheel 126 is in the down position, asdepicted in FIG. 9, the right metal edge will be bent downward and willexit through arm 170 of exit slots 166. The right metal edge will exitthrough arm 172 of exit slot 166 if cam wheel 126 is in the up positionas depicted in FIG. 8 and the right sheet metal edge is not finallyformed or bent. Thus, during fabrication of sheet metal, cutting arm 150is retained in the up position as shown in FIG. 6 until the appropriatelength of metal is formed and advanced through slots 166 and 168.Cutting arm 150 is then pushed downward as shown in FIG. 7 and theappropriate length of formed sheet metal is cut or sheared at thedesired location.

To retain cutting arm 150 in the “up” position during fabrication and asa safety measure, rotating support arm 174 is provided. Duringfabrication, rotating support arm 174 is in the position shown in FIG. 6with portion 178 thereof supporting cutting arm 150. To cut, cutting arm150 is lifted slightly, support arm 174 rotated 90° to the positionshown in FIG. 7 and cutting arm 150 depressed as shown in FIG. 7 to cutmetal that has exited slots 166.

The metal forming apparatus 10 of the instant invention is generallydesigned to fabricate sheet metal at a width of about 8 inches, but itwill be readily understood that both wider and narrower such devices canbe similarly manufactured for the fabrication of narrower and widersheet metal.

Payoff 14 has been depicted in FIG. 1 as a roll core having sides. Whilesuch a payoff has been found to provide adequate results, in use it hasbeen determined that the use of such a structure for payoff 14 canresult in binding of sheet metal to be formed as the metal transitionsfrom the horizontal orientation on payoff 14 to the vertically offsetposition required for proper entry into grooves 38 and 40 in verticallyoffset guide bars 34 and 36. In order to eliminate this transitionalstress and the resultant deformation or binding of the sheet metal, theuse of a novel self adjusting payoff device 200 as depicted in FIGS. 1aand 1 b is preferred.

Referring now to FIGS. 1a and 1 b, the preferred payoff 200 comprises asupporting frame 212 and a pivoting spool 214. Supporting frame 212 maybe of any design so long as it provides controlled payout of strip froma coil 224 mounted on pivoting spool 214. Supporting frame 212 depictedin FIG. 1b, comprises a base 216 and a pair of vertically extendingparallel arms 218. Atop each of parallel arms 218 is a bearing 220. Inthe case depicted in FIG. 1b, bearing 220 is a simple polymeric archsized to receive an axle 219 placed therein and to permit low speedrotation thereof. In order to assure that axle 219 does notinadvertently extricate itself from bearing 220, some type of locking orsecuring mechanism 222 is preferably provided. Locking mechanism 222, inaddition to securing axle 219 in place atop parallel arms 218 alsoserves as a brake, controlling the rotation of axle 219 therebypreventing a coil 224 of, for example metal, mounted on pivoting spool214 from “springing” or expanding as such configurations of metal stripare prone to do when left unconstrained or secured.

In the embodiment depicted in FIG. 1b, locking mechanisms 222 eachcomprise rotating latches 226 and 228. When depressed, i.e. rotateddownward, recesses 230 in latches 226 engage the extremities of axle219. Upward rotation of latches 228 then permits engagement of threadedshafts 232 with slots 234 in latches 226 by rotation of threaded shafts232 about axles 236 through which they are threaded. Turning of threadedshaft heads 238 then permits tightening of locking/braking mechanisms222 and adjustment of the amount of tension placed on axle 219 andconcomittantly coil 224 mounted on pivoting spool 214.

The core of the improved payoff of the present invention is pivotingspool 214. As shown in the various Figures, but initially, FIG. 1,pivoting spool 214 comprises an axle 219 having extremities 240 and 242.Inboard of extremities 240 and 242 are threaded portions 244 and 246located adjacent each of extremities 240 and 242. Threaded over threadedportions 244 and 246 are adjustment wheels 248 and 250 that movelaterally along axle 219 when they are turned and threads 252 and 254 atthe interior of adjustment wheels 248 and 250 engage threaded portions244 and 246. According to the particular embodiment depicted in thedrawings, adjustment wheels 248 and 250 also include attached annulargrooves 256 and 258 integral with adjustment wheels 248 and 250.

Inboard of adjustment wheels 248 and 250 are annular collars 260 and 262having at least three flanges 264 a, 264 b and 264 c extending radiallyat angles of about 120° therefrom. Annular collars 260 and 262 slideaxially and freely along the surface of axle 219. The axial motion ofannular collars 260 and 262 is controlled by the presence of tabs 266and 268 that extend axially and outwardly from annular collars 260 and262 and ends 270 and 272 of tabs 266 and 268 engage annular grooves 256and 258 that form parts of adjustment wheels 248 and 250. Tabs 266 and268 can be welded to annular collars 260 and 262 or formed integrallytherewith as machined or cast parts. Thus, as adjustment wheels 248 and250 are turned and threads 252 and 254 advance or retreat over engagingthreads 244 and 246 on axle 219, annular collars 260 and 262 are causedto move axially along axle 219 through the engagement of ends 270 and272 with annular grooves 256 and 258. Annular collars 260 and 262 arealso preferably provided with slots 274 and 276 that engage stops 278and 280 that extend axially from axle 219. The combination of stops 278and 280 in slots 274 and 276 respectively limit the axial travel ofcollars 260 and 262 assuring that they cannot be removed, evenaccidentally, from axle 219.

As will be obvious to the skilled artisan, more than three flanges maybe extended from annular collars 260 and 262 to provide the coil supportrequired. Whatever number of such elements are utilized the structureshould be such as to not interfere with the operation of the pivotingspool as described herein.

Extending generally radially from and attached rotatably to flanges 264a, 264 b and 264 c are arm pairs 282 a, 282 b and 282 c. All of armpairs 282 a, 282 b and 282 c are of equal length. According to theembodiment depicted in the drawings, arm pairs 282 a, 282 b, and 282 care attached to flanges 264 a, 264 b and 264 c by the simple expedientof penetrating pins 284 a, 284 b and 284 c that pass through flanges 264a, 64 b and 264 c and arm pairs 282 a, 282 b and 282 c allowing armpairs 282 a, 282 b and 282 c to freely rotate about penetrating pins 284a, 284 b and 284 c. Although in the embodiment depicted in the Figures,each of arm pairs 282 a, 282 b and 282 c is shown as comprising two armslocated on either side of flanges 264 a, 264 b and 264 c a single membermay be substituted for the two arm structure so long as appropriaterotational freedom is retained.

At the outer extremities 286 a, 286 b and 286 c of arm pairs 282 a, 282b and 282 c are coil supports 288 a, 288 b and 288 c that are similarlyrotatably attached to arm pairs 282 a, 282 b and 282 c by penetratingpins 290 a, 290 b and 290 c. In their fully extended position from axle219 as shown in FIG. 1c, or their most closed position (not shown), coilsupports 288 a, 288 b and 288 c lie parallel to axle 219, but as will beexplained below, they may, depending upon the location of adjustment ofadjustment wheels 248 and 250, assume positions angularly disposed toaxle 219. Coil supports 288 a, 288 b and 288 c also preferablyincorporate stop pairs 292 a, 292 b and 292 c. These elements inhibitexcessive rotation and consequent collapse of coil supports 288 a, 288 band 288 c against axle 219. As will be apparent to the skilled artisan,a number of other similar expedients may be utilized to accomplish thesame result. For example, similar stops (not shown) could beincorporated in flanges 264 a, 264 b and 264 c at the base of arm airs282 a, 282 b and 282 c to similarly inhibit excessive travel and hencecollapse of coil supports 288 a, 288 b and 288 c against axle 219. Coilsupports 288 a, 288 b and 288 c are preferably sized to fit the width ofthe particular coil 224 applied thereto.

It is this capability of payoff apparatus 2000 to assume angularlydisposed relationships with respect to axle 219 that provides theflexibility needed to permit applied coil 224 to assume an angularposition relative to axle 219. This flexibility allows strip materialremoved from coil 224 to enter parallel but vertically offset grooves 38and 40 without buckling or otherwise deflecting. The flexibility ofpayoff 200 imparted by the rotatable attachment of arm pairs 282 a, 282b and 282 c to flanges 264 a, 264 b and 264 c and coil supports 288 a,288 b and 288 c permits payoff 200 to self adjust to orient coil 224 atthe optimum angle to permit removal of strip from coil 224 with minimumresistance and buckling or bending.

In use, the payoff apparatus of the present invention is utilized bylocating frame 212 at the entry end of a suitable metal strip formingdevice. Pivoting spool 214 is inserted into the center of a suitablecoil of metal after adjustment wheels 248 and 250 have been threadedinward as far as they can travel against stops 278 and 280, whichpresents the narrowest diameter of extension for pivoting spool 214.Coil 224 is then centered upon coil supports 288 a, 288 b and 288 c andadjustment wheels 248 and 250 then screwed outwardly, preferably inunison until coil supports 288 a, 288 b, and 288 c push securely againstthe inner surface of coil 224. Pivoting spool 214 with coil 24 mountedthereon is then inserted into frame 212 as shown in FIG. 1a andlocking/braking mechanisms 222 tightened as described hereinabove to theappropriate tightness to allow controlled removal of strip from coil224. Because of the free rotational structure of arm pairs 282 a, 282 b,and 282 c with respect to flanges 264 a, 264 b and 264 c and coilsupports 288 a, 288 b, and 288 c pivoting spool 214 self adjusts to theappropriate angle relative to axle 219 to permit non-binding removal ofmetal strip from coil 224 into parallel but vertically offset guides 34and 36. The self adjusting capability of pivoting spool 214 allows coil224 to be controllably angularly displaced with respect to axle 219. Inthis fashion, metal strip can be drawn from coil 224 with no tendencyfor the metal to be distorted by lateral forces normally be applied tothe metal from coil 224 as it is pulled from a true horizontal positionto a somewhat tilted toward the vertical position as is required toproperly enter parallel but vertically offset edge guides 34 and 36.

There has thus been described a compact portable and easily handoperated sheet metal forming device suitable for mounting on the siderail of a pick-up truck and that is capable of producing custom lengthsof at least two discrete commonly used flashing shapes.

As the invention has been described, it will be apparent to thoseskilled in the art that the same may be varied in many ways withoutdeparting from the spirit and scope of the invention. Any and all suchmodifications are intended to be included within the scope f theappended claims.

What is claimed is:
 1. In combination; a) a sheet metal formingapparatus having parallel but vertically offset guide mechanisms; and b)a self-adjusting payoff capable of feeding sheet metal to said parallelbut vertically offset guide mechanisms comprising: I) a frame; and ii)mounted in the frame a pivoting spool comprising; 1) an axle; 2) atleast three pivot assemblies slidably mounted on the axle and comprisingat least three arm pairs having opposing ends extending radially fromand attached rotatably to annular collars about the axle at one of theopposing ends and each of said arm pairs rotatably attached to coilsupports at the other opposing ends; and 3) an adjustment mechanism foradjusting the pivot assemblies relative to the axle.
 2. In combination;I) a self-adjusting payoff comprising: A) a frame; and B) mounted in theframe a pivoting spool comprising; a) an axle; b) at least three pivotassemblies slidably mounted on the axle and comprising at least threearm pairs having opposing ends extending radially from and attachedrotatably to annular collars about the axle at one of the opposing endsand each of said arm pairs rotatably attached to coil supports at theother opposing ends; and C) an adjustment mechanism for adjusting thepivot assemblies relative to the axle; and II) a compact, portable sheetmetal forming apparatus comprising: a) a frame having an entry and anexit end and opposing sides; b) an internal frame formed by theinsertion of a downward extending flange between said opposing sides; c)parallel, offset slotted guide bars extending outwardly from said entryend that guide sheet metal to be formed; d) a series of at least twoforming roll pairs arranged to receive said sheet metal from said guidebars comprising: I) a forming roll mounted on a shaft having first andsecond ends journaled in said opposing sides; and II) a drive rollmounted on a shaft having first and second ends, said first endjournaled in said downward extending flange and said second endjournaled in one of said sides; e) a handle attached to said first endof one of said forming roll shafts; f) interlocking gears attached tosaid second ends of said forming roll and said drive roll shaftsdrivingly connected with each other; g) interlocking transfer gearsmounted on shafts journaled in said one side in which said second endsare journaled and drivingly engaging at least one of said interlockinggears of each of said forming roll pairs; h) downstream of said at leasttwo forming roll pairs, proximate one of said side walls an adjustableedge forming assembly comprising: 1) a cam wheel; and 2) a guide rollfacing said cam wheel; and i) a guillotine cutter forming said exit endfor selectively cutting custom lengths of sheet metal formed in saidmetal forming apparatus.
 3. The combination of claim 1 wherein saidforming rolls are coated with a tough nylon coating.
 4. The combinationof claim 1 wherein said guillotine cutter comprises a cutting bladelocated between a pair of plates, said plates having slots therein inthe shape of sheet metal formed in the forming apparatus and saidcutting blade having a slot therein that lies in registration with saidplate slots when said forming apparatus is operating, said cutting bladeslot being larger than said plate slots but similarly adapted to permitthe passage of sheet metal formed in said forming apparatus.
 5. Thecombination of claim 4 wherein said forming rolls are coated with atough nylon coating and said drive rolls are at least partially coatedwith an adherent material that permits gripping of the surface ofinserted sheet metal.
 6. The combination of claim 4 wherein said formingrolls include a tapered forming portion and that portion of said driverolls proximate said tapered forming portion are coated with a toughnylon coating.
 7. The combination of claim 2 further including aplatform to which said sheet metal forming apparatus is fastened andsaid payoff is attached to said platform near said entry end such thatsheet metal on said payoff may be fed to said verically offset parallelguide bars for introduction into said sheet metal forming apparatus. 8.The combination of claim 2 wherein said handle includes an engagementportion that slips over said first end of one of said forming rollshafts and is fastened thereto by means of a fastener that penetratessaid engagement portion and said forming roll shaft to permit attachmentthereof during operation and removal thereof in transit.
 9. Thecombination of claim 2 wherein said adjustable edge forming assemblycomprises: A) an angularly oriented cam wheel attached to: B) avertically indexable slide arm that moves up and down in: C) a channelbracket attached to one of said sides; D) a set bolt or screw in saidchannel bracket for setting said indexable slide arm in at least twodifferent positions; and E) a guide roll that addresses the cam wheel topermit forming of the edge of sheet metal forced between said cam wheeland said guide roll.
 10. The combination of claim 1 wherein saidself-adjusting payoff comprises; A) a frame; and B) a pivoting spoolmounted in said frame and comprising: 1) an axle having opposingextremities; 2) threaded portions proximate each of said opposingextremities; 3) adjustment wheels having interior threads rotatablyengaging said threaded portions and including axial extensionsincorporating an annular groove; 4) a pair of annular collars slideablyabout said axle intermediate said adjustment wheels and including tabsthat engage said annular grooves; 5) at least three arm pairs havingopposing ends extending radially from and attached rotatably to saidannular collars at one of said opposing ends; and 6) at least three coilsupports rotatably attached to the other of said opposing ends therebyjoining each of said arm pairs.
 11. The combination of claim 10 whereinsaid arm pairs are of equal length.
 12. The combination of claim 10wherein said frame includes a pair of bearings for receipt of saidopposing ends of said axle and a braking mechanism for controlling thespeed of rotation of said axle.
 13. The combination of claim 12 whereinsaid braking mechanism comprises a slotted bracket that rotates oversaid bearing and said axle, and a threaded locking bolt that rotatablyengages said slot.
 14. A compact, portable sheet metal forming apparatuscomprising: A) a frame having an entry and an exit end and opposingsides; B) an internal frame formed by the insertion of a downwardextending flange between said opposing sides; C) parallel, offsetslotted guide bars extending outwardly from said entry end that guidesheet metal to be formed; D) a series of at least two forming roll pairsarranged to receive said sheet metal from said guide bars comprising: I)a forming roll mounted on a shaft having first and second ends journaledin said opposing sides; and II) a drive roll mounted on a shaft havingfirst and second ends, said first end journaled in said downwardextending flange and said second end journaled in one of said sides; E)a handle attached to said first end of one of said forming roll shafts;F) interlocking gears attached to said second ends of said forming rolland said drive roll shafts drivingly connected with each other; G)interlocking transfer gears mounted on shafts journaled in said one sidein which said second ends are journaled and drivingly engaging at leastone of said interlocking gears of each of said forming roll pairs; H)downstream of said at least two forming roll pairs, proximate one ofsaid side walls an adjustable edge forming assembly comprising: I) a camwheel; and II) a guide roll facing said cam wheel; I) downstream of saidforming rolls and proximate the side wall oppostie said adjustable edgeforming assembly, a pencil beading assembly comprising a slotted blockincluding a barbell shaped forming roll and a facing bead roll; and J) aguillotine cutter forming said exit end for selectively cutting customlengths of sheet metal formed in said metal forming apparatus.